Abstract

This research presents the process of designing a non metal pedal box system
for Proton Wira car. Closed form or non-numerical data analysis of non metal
pedal box system is initially carried out. Calculations of bending stiffness and
torsion strength to decide on the best pedal lever cross section were carried out.
Similarly yield stress calculation for pedal lever was performed. Comparison
between non metal pedal box system and steel pedal box system was carried
out. This research also includes the measuring process with a coordinate
measuring machine of the currently used steel pedal box system and followed
by modelling the design in Unigraphics. The design of three pedals namely an
accelerator pedal, a brake pedal and a clutch pedal as well as a mounting
bracket was carried out. Rapid prototyping models using stereo lithography
(SLA 3500) by 3D System and 3D Printer Z40L. by Z-corp were produced.
Stereolithography and 3D printing were compared in terms of cost, speed of the
process, user friendliness and model quality. The purpose of rapid prototyping
models is to facilitate easy communication of product to the customers.methods of rapid prototyping using various approaches and to decide on the
best methods in term of quality, cost and speed of processing. Design
communication using rapid prototyping is one of the important elements of
concurrent engineering technique. The pedal box' system was designed to meet
the final objective of weight reduction produced using injection moulding
process.